U.S. patent application number 16/649352 was filed with the patent office on 2020-07-09 for multi-laminate plastic carrier plate and method for the production thereof.
The applicant listed for this patent is AKZENTA PANEELE + PROFILE GMBH. Invention is credited to Hans-Jurgen HANNIG, Felix HULLENKREMER.
Application Number | 20200215801 16/649352 |
Document ID | / |
Family ID | 63962763 |
Filed Date | 2020-07-09 |
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United States Patent
Application |
20200215801 |
Kind Code |
A1 |
HANNIG; Hans-Jurgen ; et
al. |
July 9, 2020 |
MULTI-LAMINATE PLASTIC CARRIER PLATE AND METHOD FOR THE PRODUCTION
THEREOF
Abstract
The present disclosure relates to a multi-laminate plastic
carrier plate having a plurality N of A-B-A layer sequences,
wherein the A layer includes a first thermoplastic resin and the B
layer includes a second thermoplastic resin, and wherein the first
thermoplastic resin is a virgin plastic and the second plastic is a
recycled plastic, and wherein 250.gtoreq.N.gtoreq.2, preferably
200.gtoreq.N.gtoreq.3, preferably 125.gtoreq.N.gtoreq.4, still more
preferably 100.gtoreq.N.gtoreq.5.
Inventors: |
HANNIG; Hans-Jurgen;
(Bergisch Gladbach, DE) ; HULLENKREMER; Felix;
(Koblenz, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AKZENTA PANEELE + PROFILE GMBH |
Kaisersesch |
|
DE |
|
|
Family ID: |
63962763 |
Appl. No.: |
16/649352 |
Filed: |
August 13, 2019 |
PCT Filed: |
August 13, 2019 |
PCT NO: |
PCT/EP2019/071762 |
371 Date: |
March 20, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2451/00 20130101;
B32B 2272/00 20130101; B32B 27/16 20130101; B32B 2307/732 20130101;
B32B 27/304 20130101; B32B 2419/04 20130101; B32B 21/10 20130101;
B32B 2250/05 20130101; B32B 2255/02 20130101; B32B 7/022 20190101;
B32B 27/08 20130101; B32B 2264/102 20130101; B32B 3/02 20130101;
B32B 27/36 20130101; B32B 2250/244 20130101; B32B 27/10 20130101;
B32B 37/02 20130101; B32B 2307/518 20130101; E04F 15/105 20130101;
B32B 27/302 20130101; B32B 2255/10 20130101; B32B 27/12 20130101;
B32B 2307/306 20130101; B32B 37/00 20130101; B32B 2255/08 20130101;
B32B 2255/26 20130101; B32B 2307/558 20130101; B32B 2264/067
20130101; B32B 2307/718 20130101; B32B 2307/734 20130101; B32B 7/12
20130101; B32B 27/20 20130101; B32B 5/26 20130101; B32B 2264/10
20130101; B32B 21/06 20130101; B32B 2307/554 20130101; B32B
2307/7246 20130101; E04F 13/18 20130101; B32B 7/04 20130101; B32B
27/32 20130101; B32B 2264/04 20130101; B32B 5/022 20130101; B32B
2419/00 20130101; B32B 2307/54 20130101; B32B 29/02 20130101; B32B
2250/40 20130101; B32B 2607/00 20130101 |
International
Class: |
B32B 27/08 20060101
B32B027/08; B32B 27/20 20060101 B32B027/20; B32B 27/36 20060101
B32B027/36; B32B 37/02 20060101 B32B037/02; E04F 13/18 20060101
E04F013/18; E04F 15/10 20060101 E04F015/10 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 14, 2018 |
DE |
10 2018 119 766.7 |
Claims
1. A multi-laminate plastic support material having a plurality N
of A-B-A layer sequences, wherein the A layer includes a first
thermoplastic resin and the B layer includes a second thermoplastic
resin, and wherein the first thermoplastic resin is a virgin
plastic and the second plastic is a recycled plastic, and wherein
250.gtoreq.N.gtoreq.2, preferably 200.gtoreq.N.gtoreq.3, preferably
125.gtoreq.N.gtoreq.4, still more preferably
100.gtoreq.N.gtoreq.5.
2. The multi-laminate plastic support material according to claim
1, wherein the recycled thermoplastic resin of the B layer includes
an amorphous polyethylene terephthalate (PET).
3. The multi-laminate plastic support material according to claim
1, wherein the B layer includes a filler material besides the
thermoplastic resin, wherein the filler material is preferably
selected from the group consisting of chalk, non-asbestos silicate,
preferably magnesium silicate, sawdust, expanded clay, volcanic
ash, pumice, aerated concrete, in particular includes inorganic
foams, cellulose or an expanding agent.
4. The multi-laminate plastic support material according to claim
3, wherein the proportion of filler material is in a range between
.gtoreq.1 wt % and .ltoreq.60 wt % relative to the total weight of
the material that forms the B layer.
5. The multi-laminate plastic support material according to claim
1, wherein the thermoplastic resin of the A layer includes a
glycol-modified polyethylene terephthalate (PET-G).
6. The multi-laminate plastic support material according to claim
1, wherein the layer thickness of the B layer has a value between
100% and 3000% of the layer thickness of the A layer.
7. The multi-laminate plastic support material according to claim
1, wherein the plastic support material has a shrinkage of
.gtoreq.0.25% at 80.degree. C. according to ISO 23999.
8. The multi-laminate plastic support material according to claim
1, wherein at least a part of the film-like multilayer composites
with the layer sequence A-B-A is stretched biaxial.
9. A method for producing a multi-laminate plastic support material
including the steps: a) Producing a first film-like multilayer
composite with the layer sequence A-B-A, wherein the A layer
contains a first thermoplastic resin, and the B layer contains a
second thermoplastic resin; b) Placing a plurality N of first
film-like multilayer composites with the layer sequence A-B-A one
on top of the other to form a layer stack, wherein
250.gtoreq.N.gtoreq.2, preferably 200.gtoreq.N.gtoreq.3, preferably
125.gtoreq.N.gtoreq.4, more preferably still 100.gtoreq.N.gtoreq.5;
c) Compressing the layer stack using the effects of pressure and
temperature; and d) Cooling the compressed layer stack.
10. The method according to claim 9, wherein the film-like
multilayer composite with the layer sequence A-B-A is produced by
feeding the first and second thermoplastic resins into a feedblock
and extruding them through a sheet extrusion die.
11. The method according to claim 9, wherein at least a part of the
film-like multilayer composites with the layer sequence A-B-A is
stretched biaxially before being placed one on top of the other to
form the layer stack.
12. The method according to claim 9, wherein after the compression
in step c) the multi-laminate plastic support material is cooled to
a temperature .ltoreq.40.degree. C. and subsequently heated to a
temperature above the glass transition temperature of the plastic,
in particular to a temperature in a range between
.gtoreq.90.degree. C. and .ltoreq.110.degree. C.
13. The method according to claim 12, wherein the multi-laminate
plastic support material is heated for a period from 0.5 to 5
minutes, preferably 1 to 4 minutes, in particular 1.5 to 3 minutes
to a temperature above the glass transition temperature of the
plastic.
14. A decorative panel including a support board, a decoration
arranged on the support board, a covering layer arranged over the
decoration and optionally corresponding locking means on at least
two side edges of the panel, wherein the support board is a
multi-laminate support board according to claim 1 and the
decorative panel undergoes shrinkage .ltoreq.0.25% at 80.degree. C.
for 6 h according to ISO 23999.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a National Phase of International
Application No. PCT/EP2019/071762 filed on Aug. 13, 2019. This
application claims the benefit of German Patent Application No. 10
2018 119 766.7, filed on Aug. 14, 2018. The entire disclosures of
the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a multi-laminate plastic
carrier plate and a method for production thereof. The present
disclosure relates in particular to a multi- laminate plastic
carrier plate for producing decorative wall, ceiling and floor
panels and a method for producing such decorative panels.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] Decorated panels as such are known, wherein the term wall
panel is also understood to include panels which are suitable for
cladding ceilings or doors. They typically consist of a carrier or
core made from a solid material, for example a wood material, such
as a medium density fibreboard (MDF) or high density fibreboard
(HDF, a wood-plastic composite (WPC) or a mineral-plastic composite
(MPC), at least one side of which is furnished with a decorative
layer and a covering layer, and optionally with further layers, for
example a wear layer arranged between the decorative and the
covering layer. In the case of MDF or HDF supports, the decorative
layer is typically applied to a print substrate arranged on the
support, which substrate may consist of a paper layer. In this
context, it is known to print the decorative layer on the paper
layer before the paper layer is applied to the support, or also to
apply an initially unprinted paper layer to the support and then to
apply the decorative layer to the paper layer by means of direct
printing processes. In the case of supports based on plastic
composites, it is known to furnish said supports with a decoration
after optionally applying a print substrate in a direct printing
process.
[0005] A disadvantage of the supports based on wood materials is
often the only limited resistance to moisture of the resulting
decorative panels, with the consequently limited range of uses of
such panels. Therefore, in recent years more and more plastic-based
supports have been developed in order to extend the field of
application of corresponding decorative panels. However, it is
precisely in the field of plastic-based supports that there is
still development potential by which they might be improved in both
ecological and economical terms.
[0006] EP2 757 129 A1 discloses a decorative panel which has a
board-like substrate which is at least partly made from a
thermoplastic composition modified using an elastomer powder. The
suggested decorative panel has at least one board-like substrate
and a decorative layer arranged thereon, wherein the board-like
substrate is at least partly made from a thermoplastic composition
which is modified by melt blending with an elastomer powder having
at least one thermoplastic material and at least one fine grained,
crosslinked and powdery elastomer material incorporated in the
matrix material.
[0007] WO 2014/029887 A1 discloses a method for producing a
decorated wall or floor panel, including the method steps a)
providing a board-like support, b) applying a primer at least to
the surface of the board-like support which is to be printed, c)
applying a decoration by means of printing to at least a part of
the surface that was treated with the primer, which is
characterized in that a liquid, radiation-curable mixture on a
urethane acrylate base is used as the primer.
[0008] EP 2 942 208 A1 discloses a method for producing a decorated
wall or floor panel, including the method steps: a) providing a
free-flowing carrier material, in particular a granulate, b)
arranging the carrier material between two belt-like conveying
means, c) shaping the carrier material using the action of
temperature to form a web-like carrier, d) compressing the carrier,
e) treating the support using the action of pressure by means of a
dual-band press, wherein the support is cooled in or in front of
the dual-band press; f) optionally further cooling the carrier, g)
optionally applying a decorative substrate to at least a portion of
the carrier; h) applying a decor which simulates a decorative
pattern to at least one partial region of the carrier, i) applying
a protective layer to at least a portion of the decoration, j)
optionally structuring the protective layer for inserting pores
and/or the edge region of the carrier for forming connecting
elements, and k) optionally treating the carrier for electrostatic
discharge before one of the aforementioned method steps.
[0009] EP 3 088 204 A1 discloses a method for producing a decorated
wall or floor panel, including the method steps: a) providing a
free-flowing carrier material, in particular a granulate, b)
arranging the carrier material between two belt-like conveying
means, c) shaping the carrier material using the action of
temperature to form a web-like carrier, d) compressing the carrier,
e) treating the support using the action of pressure by means of a
dual-band press, wherein the support is cooled in or in front of
the dual-band press; f) optionally further cooling the carrier, g)
optionally applying a decorative substrate to at least a portion of
the carrier; h) applying a decor which simulates a decorative
pattern to at least one partial region of the carrier, i) applying
a protective layer to at least a portion of the decoration, wherein
j) a film made from a moisture-absorbing material is arranged below
or above the carrier material before the carrier material is
arranged between two belt-like conveying means in accordance with
method step b).
SUMMARY
[0010] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features
[0011] It is the object of the present disclosure to suggest an
improved plastic-based support material which is suitable in
particular for producing decorated wall, ceiling and floor
panels.
[0012] Preferred variants of the disclosure are described in the
subclaims, the description or the figures, wherein further features
described or illustrated in the subclaims, the description or the
figures in any combination may constitute an object of the
disclosure unless the contrary is unequivocally evident from the
context. In particular, the quantities and properties of the
respective materials and substances indicated in the following text
may be combined with each other in any way desired.
[0013] With the disclosure, a multi-laminate plastic support
material is suggested which contains a plurality N of layer
sequences A-B-A, wherein the A layer includes a first thermoplastic
resin and the B layer includes a second thermoplastic resin, and
wherein the first thermoplastic resin is a virgin resin and the
second resin is a recycled resin, and wherein
250.gtoreq.N.gtoreq.2, preferably 200.gtoreq.N.gtoreq.3, preferably
125.gtoreq.N.gtoreq.4, still more preferably
100.gtoreq.N.gtoreq.5.
[0014] Surprisingly, it was demonstrated that a plastic support
material of such kind can be used to produce a wall, ceiling or
floor panel with improved moisture resistance, in particular with
reduced swelling caused by moisture or heat, and with good
mechanical properties and improved workability. Moreover, the
plastic support material according to the disclosure is
ecologically advantageous, as a considerable portion thereof can be
manufactured from recycled plastic and it is thus economical in
terms of resources.
[0015] Within the scope of the disclosure, the term "decorated wall
or floor panel" or "decorative panel" is understood to mean in
particular wall, ceiling, door or floor panels which have a
decoration that simulates a decorative template and has been
applied to a support board. In this context, decorative panels are
used in a wide range of applications not only in interior design
but also for the decorative panelling of structures in trade fair
construction, for example. One of the most common areas of
utilisation for decorative panels is their use as floor covering.
In this context, the decorative panels often include a decoration
which is intended to resemble a natural material.
[0016] Examples of such imitated natural materials or decorative
templates are wood types such as maple, oak, birch, cherry, ash,
walnut, chestnut, wenge or also exotic woods such as panga-panga,
mahogany, bamboo and bubinga. Natural materials such as stone
surfaces or ceramic surfaces are also imitated frequently.
[0017] Accordingly, within the scope of the present disclosure the
term "decorative template" may be understood in particular to mean
an original natural material of such kind, or at least a surface of
such, which is to be imitated or simulated by the decoration.
[0018] A "free-flowing" material may be understood in particular to
describe a material which may be applied to a foundation in a
pouring by a pouring operation or a spreading operation. In this
context, the material may exist as a fluid or in particular as a
free-flowing solid.
[0019] In addition, a "granulate" or "granular material" may be
understood to describe a solid or a solid aggregate which comprises
or consists of a multiplicity of solid particles such as grains or
beads. Granular or powdery materials may be cited as examples of
these, although the list is not limited thereto.
[0020] A "support" may be understood in particular to refer to a
completed panel as the core or a layer serving as the base layer,
which in particular may contain a natural material such as a wood
material, a fibre material or a material that comprises a plastic.
For example, the support may already lend the panel a suitable
stability or contribute thereto.
[0021] Accordingly, a support material may be understood to be such
a material that constitutes at least the major part of the support.
In particular, the support may consist of the support material.
[0022] In this context, a "web-like support" may be understood to
refer to a support which for example as a result of its
manufacturing process has a length which is web-like and thus
considerably larger than its width and thickness, and of which the
length may be greater than 15 metres, for example.
[0023] Also within the meaning of the present disclosure, in this
context a "board-like support" may also be understood to be a
support which is formed by separation from the web-like support and
is constructed in the shape of a board. The board-like support may
also predefine the shape and/or size of the panel that is to be
produced. However, the board-like support may also be provided as a
large panel. A large panel within the meaning of the disclosure is
in particular a support whose dimensions are larger than the
dimensions of the eventual decorative panel by a multiple thereof
and which is divided into a corresponding plurality of decorative
panels during the manufacturing process, for example by sawing, or
cutting by laser beam or water jet. The large panel may correspond
to the web-like support, for example.
[0024] A support material as described previously thus serves in
particular for producing a support for a decorated wall or floor
panel. The support material essentially includes two materials,
wherein within the meaning of the present disclosure a material may
be understood to be either a homogeneous material, that is to say a
material formed from only a single substance, or also a
heterogeneous material, that is to say a material consisting of at
least two substances, wherein the material consisting of at least
two substances may thus also be understood to be a substance
mixture.
[0025] According to one variant of the disclosure, layers A and B
each have a layer thickness between 100 .mu.m and 2000 .mu.m. In
this context, it may be provided that the layer thickness of the A
layer is different from the layer thickness of the B layer.
Accordingly, it may be provided for example that the B layer has a
layer thickness which is equal to .gtoreq.100% to .ltoreq.1000% of
the layer thickness of the A layer. In a further variant, it may be
provided that the layer thickness of the A layer has a layer
thickness which is equal to .gtoreq.100% to .ltoreq.1000% of the
layer thickness of the B layer. In another variant of the
disclosure, it may be provided that the layer thickness of the two
A layers are different from one another.
[0026] According to a further variant of the disclosure, it may be
provided that the recycled thermoplastic resin B layer includes an
amorphous polyethylene terephthalate (PET). Large quantities of
polyethylene terephthalate (PET) are encountered in the packaging
industry, where it is used particularly for food packages and
beverage bottles. Since the highest standards must be maintained in
the domain of food packaging, there is usually only limited scope
for recycling PET. Furthermore, despite the recycling processes
that are now available, such as the United Resource Recovery
Corporation (URRC) process, large quantities of PET are not
recycled locally, but instead they are exported for manufacturing
synthetic fibres. In this regard too, the process according to the
disclosure offers a further option for using recycled PET.
[0027] The proportion of recycled polyethylene terephthalate in the
B layer may preferably be in a range between .gtoreq.10 wt % and
.ltoreq.100 wt % relative to the polymer content in the B layer.
The proportion of recycled polyethylene terephthalate in the B
layer may particularly preferably be in a range between .gtoreq.15
wt % and .ltoreq.90 wt %, .gtoreq.20 wt % and .ltoreq.80 wt %, in
particular relative to the polymer content in the B layer.
[0028] Besides the recycled polyethylene terephthalate, virgin
polyethylene terephthalate may be provided in the B layer. In this
context, the proportion of virgin PET may be in a range between
.gtoreq.0 wt % and .ltoreq.90 wt % relative to the polymer content
in the B layer. The proportion of virgin polyethylene terephthalate
in the B layer may particularly preferably be in a range between
.gtoreq.10 wt % and .ltoreq.80 wt %, .gtoreq.15 wt % and .ltoreq.75
wt % in particular relative to the polymer content in the B layer.
An improved bond with layers A may be achieved with the provision
of virgin PET.
[0029] According to a further variant of the disclosure, it may be
provided that the B layer contains a filler material besides the
thermoplastic resin, wherein the filler material is preferably
chosen from the group consisting of chalk, non-asbestos silicate,
preferably magnesium silicate, sawdust, expanded clay, volcanic
ash, pumice, aerated concrete, in particular inorganic foams,
cellulose, or contains an expanding agent.
[0030] The proportion of filler material may preferably be in a
range between .gtoreq.1 wt % and .ltoreq.60 wt %, in particular in
a range between .gtoreq.5 wt % and .ltoreq.50 wt % relative to the
total weight of the materials that makes up the B layer.
[0031] By adding filler materials, it is advantageously possible to
adjust the material properties of the multi-laminate plastic
support material such as its specific weight, or even its calorific
value. The calorific value in particular is significant with regard
to the question of the fire load represented by the wall, ceiling
or floor covering which is created on the basis of a corresponding
multi-laminate plastic support and introduced into the building. In
general, the proportions of thermoplastic resin material and filler
material may be selectable depending on the intended field of
application and the desired properties of a panel produced on the
basis of a multi-laminate plastic support material according to the
disclosure. In this way, it is possible to assure good adaptability
to the desired field of application.
[0032] It may be particularly preferably provided that a sheet
silicate, such as talcum for example, is used as the filler
material in the B layer. In this context, talcum is understood to
refer in known manner to a magnesium silicate hydrate, which may
have the molecular formula Mg.sub.3[Si.sub.4O.sub.10(OH).sub.2],
for example. Thus, at least most of the solid content is
advantageously formed by the mineral substance talcum, wherein this
substance may be used in powder form, for example, and/or it may be
present in the support material in the form of particles. In all
cases, the solid material may consist of a powdery solid.
[0033] It may be advantageous if the specific surface density
determined according to BET, ISO 4652 of the talcum particles is in
a range from .gtoreq.4 m.sup.2/g to .ltoreq.8 m.sup.2/g, for
example in a range from .gtoreq.5 m.sup.2/g to .ltoreq.7
m.sup.2/g.
[0034] It may further be advantageous if the talcum is present with
a bulk density according to DIN 53468 in a range from .gtoreq.0.15
g/cm.sup.3 to .ltoreq.0.45 g/cm.sup.3, for example in a range from
.gtoreq.0.25 g/cm.sup.3 to .ltoreq.0.35 g/cm.sup.3.
[0035] With reference to the material which forms the B layer, it
may further be provided that the thermoplastic resin material and
filler material together are present in a total quantity from
.gtoreq.95 wt %, in particular .gtoreq.99 wt %, relative to
material that constitutes the B layer. In other words, it may be
provided that additional substances other than the thermoplastic
material and the filler material are only present in the material
forming the B layer in a proportion of <5 wt %, preferably <1
wt % relative to the material constituting the B layer. Thus, it
may be advantageous that the material constituting the B layer
consists mostly of thermoplastic resin and one or more filler
materials.
[0036] It may further be provided that thermoplastic resin material
of the B layer includes further constituents such as flexibilisers,
pigments, stabilisers, impact resistance modifiers, crosslinking
and/or dispersant additives.
[0037] If pigments are provided as further constituents, it is
advantageous if the colour pigments do not contain any lead and/or
cadmium. Colour pigments used may include for example copper
phthalocyanine, quinacridone and/or diketopyrrolopyrrole. This
makes it possible to ensure that the support material can be
recycled in an environmentally compatible manner.
[0038] According to one variant of the disclosure, the recycled PET
(rPET) may have a Vicat softening temperature between
.gtoreq.70.degree. C. and .ltoreq.80.degree. C., for example
75.degree. C.
[0039] It may further be provided that the recycled PET (rPET) has
a Melting Flow Index (MFI) between .gtoreq.40 g/10 min and
.ltoreq.60 g/10 min, for example 49 g/10 min.
[0040] It may further be provided that the dimensional stability
under heat (method A: 1.82 MPa) of the rPET is in a range between
.gtoreq.63.degree. C. and .ltoreq.83.degree. C., for example at
73.degree. C.
[0041] According to one variant of the disclosure, the rPET may
have a tensile strength between .gtoreq.50 MPa and .ltoreq.70 MPa,
of 60 MPa for example.
[0042] According to one variant of the disclosure, the rPET may
have a tensile modulus in a range from .gtoreq.1500 MPa to
.ltoreq.2500 MPa, of 2000 MPa for example.
[0043] Moreover, the elongation at rupture of the rPET according to
one variant of the disclosure may be in a range between
.gtoreq.7.0% and .ltoreq.12.0%, 9.2% for example.
[0044] According to one variant of the disclosure, the rPET may
reach a Charpy impact resistance in a range between .gtoreq.20
kJ/m.sup.2 and .ltoreq.40 KJ/m.sup.2, for example 30
KJ/m.sup.2.
[0045] According to a further variant of the disclosure, if the
material of the B layer includes a mixture of recycled PET and
talcum, it may have a Vicat softening temperature in a range
between .gtoreq.70.degree. C. and .ltoreq.90.degree. C., for
example 83.degree. C. According to a further variant, the
dimensional stability under heat (A-1.82 MPa) of such a material
may be in a range between .gtoreq.70.degree. C. and
.ltoreq.90.degree. C., 80.degree. C. for example. According to a
further variant, the tensile strength of such a material may be in
a range between .gtoreq.35 MPa and .ltoreq.55 MPa, such as 45 MPa
for example. According to a further variant, the tensile modulus of
such a material may be in a range between .gtoreq.1800 MPa and
.ltoreq.2500 MPa, 2100 MPa for example. According to a further
variant, the elongation at rupture of such a material may be in a
range between .gtoreq.2% and .ltoreq.10%, and may be 4% for
example. According to a further variant, the Charpy impact
resistance of such a material may be in a range between .gtoreq.5
KJ/m.sup.2 and .ltoreq.20 KJ/m.sup.2, for example 10
KJ/m.sup.2.
[0046] According to the disclosure, it may further be provided that
different A-B-A film layers are arranged one on top of the other,
which layers may be identical with regard to the thermoplastic
resin of type A, but differ in construction of the B layer, for
example. Accordingly, it may be provided for example that a central
film of the A-B-A type is provided within the film stack, in which
the B layer has a high proportion of a filler material, for example
50 wt % relative to the total weight of the B layer, whereas the
A-B-A film layers arranged above and/or below this A-B-A film layer
have a lower proportion of filler material in the B layer, for
example 15 wt % relative to the total weight of the B layer.
[0047] It may also be provided that the A-B-A film layers stacked
one on top of the other differ in the nature of their filler
material. Accordingly, it may be provided for example, that one
A-B-A film layer contains a filler material such as talcum, and
another A-B-A film layer contains inorganic foams, cellulose and/or
an expanding agent as filler material, and that in this way the
layers of type B differ in terms of their physicochemical
properties such as density, thermal capacity or hardness.
[0048] The provision of different variants of the B layers makes it
possible to vary the overall properties of the multi-laminate
plastic support material according to the disclosure over a broad
range and to adapt the material to the desired property of a
product manufactured from said support material, e.g. a decorative
panel.
[0049] According to a further variant of the disclosure, it may be
provided that the thermoplastic resin of the A layer contains a
glycol-modified polyethylene terephthalate (PET-G). Surprisingly,
it has been found that the glycol-modified PET can function as a
sealing and/or adhesive layer between the A-B-A multilayer
composites, and thereby significantly enhances reliable bonding of
the multilayer composites with each other.
[0050] According to a variant of the disclosure, the PET-G may have
a Vicat softening temperature in a range between .gtoreq.63.degree.
C. and .ltoreq.83.degree. C., 73.degree. C. for example. According
to a variant of the disclosure, the dimensional stability under
heat (A-1.82 MPa) may have a value in a range between
.gtoreq.59.degree. C. and .ltoreq.79.degree. C., for example
69.degree. C. According to a further variant of the disclosure, the
value of the tensile strength of the PET-G may be in a range
between .gtoreq.40 MPa and .ltoreq.60 MPa, for example 50 MPa. It
may be provided that the tensile modulus is in a range between
.gtoreq.1800 MPa and .ltoreq.2300 MPa, for example 2010 MPa.
According to a further variant of the disclosure, it may be
provided that the elongation at rupture of the PET-G is in a range
between .gtoreq.100% and .ltoreq.150%, for example 130%. According
to a further variant of the disclosure, the Charpy impact
resistance of a PET-G may be in a range between .gtoreq.150
KJ/m.sup.2 and .ltoreq.250 KJ/m.sup.2, for example 190
KJ/m.sup.2.
[0051] According to a preferred variant of the disclosure, the
proportion of glycol-modified polyethylene terephthalate relative
to the thermoplastic resin of the A layer is in a range between
.gtoreq.2 wt % and .ltoreq.10 wt %.
[0052] It may further be provided that the thermoplastic resin
material of the A layer includes further constituents such as
flexibilisers, pigments, stabilisers, impact resistance modifiers,
crosslinking agents and/or dispersant additives.
[0053] According to the disclosure, it may be provided that the
layer thickness of the B layer is between .gtoreq.100% and
.ltoreq.3000% of the layer thickness of the A layer. In other
words, the B layer may have the same layer thickness as an A layer
or it may be up to 30 times thicker than said A layer. In
particular, it may be provided that largest part of the total layer
thickness of the multilayer composite A-B-A is provided by the B
layer. Accordingly, it may be provided for example that the layer
thickness of the B layer constitutes .gtoreq.50% of the total layer
thickness of the multilayer composite, preferably .gtoreq.60%,
particularly .gtoreq.70% and more preferably .gtoreq.90% of the
total layer thickness.
[0054] Surprisingly, it was found, that the provision of even thin
A layers is sufficient to bond the multilayer composites A-B-A to
each other in such manner that an extremely stable multi-laminate
plastic support material can be produced, the macroscopic
properties of which are defined substantially by the properties of
the B layer.
[0055] According to one variant of the disclosure, a multilayer
composite A-B-A may have a Vicat softening temperature in a range
between .gtoreq.63.degree. C. and .ltoreq.83.degree. C., for
example 73.degree. C.
[0056] According to one embodiment of the disclosure, the molten
mass of a multilayer composite A-B-A may have a Melt Flow Index MFI
in a range from .gtoreq.130 g/10 min to .ltoreq.190 g/10 min, for
example 160 g/10 min.
[0057] According to a variant of the disclosure, the dimensional
stability under heat (A-1.82 MPa) of a multilayer composite may be
in a range between .gtoreq.55.degree. C. and .ltoreq.85.degree. C.,
for example 70.degree. C.
[0058] According to a further variant of the disclosure, a
multilayer composite A-B-A may have a tensile strength in a range
between .gtoreq.63 MPa and .ltoreq.83 MPa, for example 73 MPa.
According to a variant of the disclosure, the tensile modulus of a
multilayer composite A-B-A may be in a range between .gtoreq.3200
MPa and .ltoreq.3900 MPa, for example 3680 MPa.
[0059] According to one embodiment of the disclosure, a multilayer
composite A-B-A may have an elongation at rupture in a range
between 2.5% and 3.5%, for example 3.1%.
[0060] According to a preferred variant of the disclosure, the
multi-laminate plastic support material according to the disclosure
has a shrinkage of .ltoreq.0.25% at 80.degree. C. according to ISO
23999.
[0061] The disclosure also relates to a method for producing a
multi-laminate plastic support material including the steps:
[0062] a) Producing a first film-like multilayer composite with the
layer sequence A-B-A, wherein the A layer includes a first
thermoplastic resin and the B layer includes a second thermoplastic
resin;
[0063] b) Placing a plurality N of first film-like multilayer
composites with the layer sequence A-B-A one on top of the other to
form a layer stack, wherein 250.gtoreq.N.gtoreq.2, preferably
200.gtoreq.N.gtoreq.3, more preferably 125.gtoreq.N.gtoreq.4, most
preferably 100.gtoreq.N.gtoreq.5;
[0064] c) Compressing the layer stack using the effects of pressure
and temperature; and
[0065] d) Cooling the compressed layer stack.
[0066] Surprisingly, it was found that a multi-laminate plastic
support material according to the disclosure may be produced easily
by means of the method according to the disclosure by first
producing a film with the layer sequence A-B-A by feeding the first
and second thermoplastic resins into a feedblock and extruding the
thermoplastic resin through a sheet extrusion die. The film
obtained in this way may then be arranged in a stack, each of the
layers of type A being arranged to face each other. The film stack
obtained thereby may then be bonded together using the effects of
pressure and temperature to form a corresponding multi-laminate
support material, wherein the layers of type A assure the material
bond between the individual A-B-A film layers.
[0067] It is particularly advantageous in this context that the
target layer thickness of the multi-laminate plastic support
material may be adjusted easily by varying the number of A-B-A film
layers which are placed one on top of the other and bonded with
each other.
[0068] At the same time, it is also possible to superpose different
A-B-A film layers which, although identical in respect of the
nature of the type A thermoplastic resin, are however different for
example in terms of the structure of the B layer.
[0069] According to one variant of the disclosure, it may be
provided in particular that the first thermoplastic resin of the
film-like multilayer composite having the layer sequence A-B-A is a
virgin plastic, and the second plastic is a recycled plastic.
[0070] It is envisaged that the process for production of the
multi-laminate plastic support material according to the disclosure
is divided into two stages. In the first, the A-B-A three-layer
film is produced by co-extrusion via a feedblock and sheet
extrusion die. In the second step, multiple films are laminated to
form a board using the effects of pressure and temperature, by
means of a dual-band press for example.
[0071] In order to manufacture the three-layer film with the layer
sequence A-B-A, a co-extrusion method may be used. This process may
make use of two co-rotating twin-screw extruders for example. A
main extruder may be used to produce the material for the middle
layer B, and it may be provided that this extruder has two lateral
feeds. These lateral feeds may be used for mixing filler
materials.
[0072] The second twin-screw extruder may be used to produce the
thermoplastic resin for two A-type layers. This extruder may also
be equipped with lateral feeds to enable mixing of additional
constituents.
[0073] In order to be able to remove any moisture and/or monomers
from the polyester melt in the extruder, provision may be made to
install a high-vacuum venting system in both twin-screw
extruders.
[0074] The polymer melts from both extruders may be introduced into
a feedblock separately from one another. While the melt from the
main extruder forms the type B middle layer, the material from the
co-extruder is directed above and below the middle layer and forms
the two type A outer layers. The three-layer melt may then be
passed through a sheet extrusion die. This die serves to create a
uniform layer distribution over the entire intended film width.
[0075] A number of different variants may be implemented for the
cooling process which is carried out subsequently. For example, the
melt may be cooled by means of a calender roller system. A chill
roll may also be used. In this context, an air knife and a vacuum
chamber may fulfil the function of ensuring that the melt lies
evenly on the chill roll. Such a method is known from the
production of cast films, for example.
[0076] According to a further variant of the disclosure, it may be
provided that at least a part of the film-like multilayer composite
with the A-B-A layer sequence is stretched biaxially before being
placed one on top of the other to form the layer stack. For the
purposes of the disclosure, biaxial stretching is understood to
mean that the film-like multilayer composites with the A-B-A layer
sequence obtained are stretched in two directions orientated
substantially orthogonally to one another, thus they are stretched
longitudinally and transversely. In this way, it is possible to
obtain the desired film thickness and reduce the grammage, and
improve the mechanical properties, e.g., strength characteristics,
increase transparency, improve cold resistance, and reduce the gas
permeability of the film layer. In particular, biaxial stretching
of the films with the A-B-A layer sequence has the effect of
increasing their tensile strength, which directly affects the
mechanical properties of the multi-laminate plastic support
material which as finally produced.
[0077] In this context, the biaxial stretching may be carried out
either sequentially, first in a first direction and then in a
second direction, or simultaneously, in both directions at the same
time, simultaneous stretching being preferred.
[0078] Before the film-like multilayer composites with the A-B-A
layer sequence are stacked to form a film stack that will be
compressed, it may be provided according to the disclosure that the
film undergoes corona treatment. It has been found that carrying
out a corona treatment helps to create an improved multilayer
composite in the eventual multi-laminate plastic support material.
In this context, the corona treatment may be carried out
immediately after the film is produced and before the films are
wound onto a reel, or immediately before the films are stacked to
form a corresponding film stack for subsequent compression
thereof.
[0079] To this extent, the film-like multilayer composite with the
layer sequence A-B-A constitutes a semi-finished product which can
be stored temporarily. Such a product may be stored preferably at
room temperature with atmospheric humidity of 50%. In these
conditions, the film-like multilayer composite may be stored
indefinitely.
[0080] It may also be provided that the film-like multilayer
composite with the layer sequence A-B-A is stacked to form a layer
stack for compression immediately after it is produced, and the
manufacturing process is designed as an in-line manufacturing
process.
[0081] The three-layer film-like multilayer composites with the
layer sequence A-B-A when stacked or positioned one on top of the
other above the A-type film layers located on the outside may be
laminated to form a continuous board material under the effects of
pressure and temperature in a preferably isobaric dual-band
press.
[0082] The press that is used may have a feed rate of 20 m/min for
example.
[0083] The three-layer film-like multilayer composites with the
layer sequence A-B-A may be fixed on dispensers in a station
corresponding to the required board thickness and layer
arrangement. For the compressing process, the three-layer film-like
multilayer composites with the layer sequence A-B-A may be
preheated to temperatures of .gtoreq.80 to .ltoreq.135.degree. C.
for example. Suitable heat sources for this may be for example a
heated roller, hot air, an IR radiator, particularly a NIR
radiator, or a microwave radiator or a combination thereof.
[0084] This is followed by a compression of the film stack,
preferably in a dual-band press. The dual-band press may preferably
be equipped with steel bands for this.
[0085] The compression time may be in a range from .gtoreq.0.5 min
to .ltoreq.20 min, preferably in a range from .gtoreq.1 min to
.ltoreq.50 min, in particular .ltoreq.2 min.
[0086] The pressure to be applied during the compression may be in
a range from .gtoreq.0.5 MPa to .ltoreq.25 MPa, preferably in a
range from .gtoreq.1 MPa to .ltoreq.15 MPa according to the
disclosure.
[0087] The target temperature in the core of the film stack may
preferably be set in a range between .gtoreq.65.degree. C. and
.ltoreq.140.degree. C., in particular in a range between
.gtoreq.80.degree. C. and .ltoreq.120.degree. C. This ensures a
good bond between the individual films.
[0088] The finished board or the finished multi-laminate plastic
support material may then be cooled preferably evenly to room
temperature. This is done for example with the aid of an air-cooled
roller in the dual-band press. Afterwards, the product maybe cut to
size and stacked for storage.
[0089] According to a further variant of the disclosure, it may be
provided that the film-like multilayer composites with the layer
sequence A-B-A are placed orthogonally to each other when stacked
in a layer stack. In this context, for the purposes of the
disclosure orthogonal positioning is understood to mean that the
films are stacked transversely to each other with regard to their
production direction, that is to say their longitudinal direction.
This arrangement makes it possible to realise a further improvement
of the mechanical properties of the final multi-laminate plastic
support material. Any longitudinal stresses induced by the
production process through the sheet extrusion die and the
calendering rollers into the individual film-like layers with the
layer sequence A-B-A are compensated by the orthogonal arrangement
and result in an anisotropic material.
[0090] In this context, it may be provided that the compressing of
the film stack takes place in a batch process, wherein the films
are aligned orthogonally to each other and are laminated together
with each other by means of a press, a multi-platen press for
example. Of course, the film-like multilayer composites with the
layer sequence A-B-A must be finished to a specific dimension in
advance for this.
[0091] The compression time may lie within a range from .gtoreq.0.5
min to .ltoreq.20 min, preferably in a range from .gtoreq.1 min to
.ltoreq.50 min, in particular .ltoreq.2 min.
[0092] According to the disclosure, the pressure that must be
applied during the compression may be in a range from .gtoreq.0.5
MPas to .ltoreq.25 Mpas, preferably in a range from .gtoreq.1 MPas
to .ltoreq.15 Mpas.
[0093] The target temperature in the core of the film stack may
preferably be set in a range between .gtoreq.65.degree. C. and
.ltoreq.140.degree. C., in particular in a range between
.gtoreq.80.degree. C. and .ltoreq.120.degree. C. This assures good
bonding between the individual films.
[0094] The finished board or the finished multi-laminate plastic
support material may then be cooled, preferably evenly, to room
temperature. This is done with the aid of an air-cooled roller in
the dual-band press, for example. Afterwards the product may
optionally be further cut to size and stored in stacks.
[0095] The disclosure also relates to decorative panels with a core
which has a multi-laminate plastic support material according to
the disclosure. Such a decorative panel may include a support board
or a core made from a corresponding multi-laminate plastic support
material, a decoration arranged on the support board, and a cover
layer arranged above the decoration. Accordingly, reference is made
to the preceding description with regard to the specific features
of the core.
[0096] The edge areas of the panel may also be structured or
profiled, in particular to enable the provision of detachable
connecting elements. In this regard, in the case of a profiling, it
may be provided within the meaning of the disclosure that a
decorative and/or functional profile is worked into at least some
of the edges of the decorative panel with the aid of suitable
material removing tools. In this context, a functional profile is
understood to be for example the creation of a groove and/or tongue
profile in one edge to design decorative panels so as to be
connectable with each other by means of the profilings created.
Particularly in the case of groove and/or tongue profiles, elastic
materials are advantageous, since it is only with such materials
that profiles of such kind can be created, which are particularly
easily manageable and stable. Thus in particular no further
materials are needed to create the connecting elements. The
multi-laminate plastic support material may enable the creation of
panels with a connection strength according to ISO 24334 of
.gtoreq.2.0 kN/m, preferably .gtoreq.4.0 kN/m, in the longitudinal
direction and .gtoreq.2.5 kN/m, preferably .gtoreq.4.5 kN/m in the
transverse direction for a joint opening of 0.2 mm.
[0097] According to a further variant of the disclosure, it may be
provided that following the compression step the multi-laminate
plastic support material may undergo a tempering step or a heat
treatment step. The effect of this is to advantageously reduce the
shrinkage of the multi-laminate plastic support material
considerably. In particular, with this step it may be possible to
reduce the shrinkage of the multi-laminate plastic support material
to a value of .ltoreq.0.25% at 80.degree. C. for 6 h according to
ISO 23999. Within the meaning of the disclosure, a tempering
process is understood to mean that the compressed multi-laminate
plastic support material is cooled to a temperature
.ltoreq.45.degree. C., preferably .ltoreq.40.degree. C., in
particular .ltoreq.35.degree. C. and then heated to a temperature
above the glass transition temperature T.sub.G of the plastic in
the plastic support material. Accordingly, the multi-laminate
plastic support material is heated to a temperature in a range
between .gtoreq.90.degree. C. and .ltoreq.110.degree. C. According
to a variant of the disclosure, the multi-laminate plastic support
material is heated to a temperature above the glass transition
temperature of the plastic, in particular to a temperature in a
range between .gtoreq.90.degree. C. and .ltoreq.110.degree. C., for
a period from 0.5 to 5 minutes, preferably 1 to 4 minutes, in
particular 1.5 to 3 minutes.
[0098] The heating as part of the previously described tempering
process may be carried out for example with the aid of IR
radiators, particularly NIR radiators (Near Infrared Radiator),
microwave radiation or combinations thereof, wherein it may be
provided in particular that a radiation of the multi-laminate
plastic support material is carried out with corresponding
radiators from above and from below, preferably at the same
time.
[0099] The optional tempering step may be carried out at any point
following the compression of the film stack in step c).
[0100] For the final production of a decorative panel using a
multi-laminate plastic support material according to the present
disclosure, the following further production steps may be provided:
[0101] e) optionally applying a decorative substrate to at least a
partial area of the support; [0102] f) optionally applying a
decoration simulating the decorative template to at least a partial
area of the support, and [0103] g) optionally applying a protective
layer to at least a partial area of the decoration. The following
steps may also be carried out in addition: [0104] h) Structuring
the protective layer, and [0105] i) Treating the support for
electrostatic discharge and optionally for electrostatic charging
before at least one of the abovementioned process steps.
[0106] Surprisingly, it was found that with the method described in
the preceding text it is possible to enable a particularly
advantageous production particularly of a support for a wall or
floor panel. Moreover, the method may be particularly advantageous
due to a use of the support material as is described in detail in
the preceding text.
[0107] In order to produce a finished panel, the method may
comprise the following method steps for the purpose of furnishing
the support with a decoration and coating said decoration with a
protective layer. In this context, the following steps are
preferably performed immediately with the manufactured web-like
support or core. However, the scope of the disclosure also extends
to the situation in which the web-like support or core is first
divided into a multiplicity of board-like supports before one of
the suitable method steps e) to g), and/or the board-like support
undergoes further treatment in the correspondingly subsequent
method steps. The following notes apply correspondingly for both
alternatives, although for the sake of simplicity in the following
text said alternatives are referred to as treatment of the
support.
[0108] A pretreatment of the support for electrostatic discharge
and optionally subsequent electrostatic charging may further be
carried out optionally initially before method step f). This may in
particular serve to avoid the occurrence of blurring while the
decoration is being applied.
[0109] According to method step e), a decorative substrate may also
be applied optionally to at least a partial area of the support.
For example, a primer may first be applied in a thickness from
.gtoreq.10 .mu.m to .ltoreq.60 .mu.m as a decorative substrate,
particularly for printing processes. In this context, a liquid,
radiation-curable mixture based on a urethane or a urethane
acrylate, optionally with one or more of a photoinitiator, a
reactive diluent, a UV stabiliser, a rheological agent such as a
thickener, radical scavenger, flow control agent, defoamng agent or
preserving agent, pigment and/or a dye may be used as the
primer.
[0110] Besides the use of a primer it is possible to apply the
decoration to a decorative paper on which a corresponding
decoration may be printed, and which may be provided perhaps by
means of a resin layer applied to the support previously as a
binding agent. Such a printing substrate is suitable not only for
flexographic printing, offset printing or silkscreen printing but
also in particular for digital printing techniques, such as inkjet
processes or laser printing processes. In order to apply the resin
layer, it may preferably be provided that a resin composition is
applied which contains as the resin component at least one compound
selected from the group consisting of melamine resin, formaldehyde
resin, urea resin, phenolic resin, epoxy resin, unsaturated
polyester resin, diallyl phthalate or mixtures thereof. In such
case, the resin composition may be applied for example in an
application quantity between .gtoreq.5 g/m.sup.2 and .ltoreq.40
g/m.sup.2, preferably .gtoreq.10 g/m.sup.2 and .ltoreq.30
g/m.sup.2. In addition, a papier or a nonwoven with a grammage
between .gtoreq.30 g/m.sup.2 and .ltoreq.80 g/m.sup.2, preferably
between .gtoreq.40 g/m.sup.2 and .ltoreq.70 g/m.sup.2 is applied to
the board-like support.
[0111] It may further be provided that the decoration is applied to
the support with the aid of a partially or fully printed decorative
film or foil. A plastic film printed with a decoration and having a
thermoplastic resin base, such as polyethylene terephthalate,
polyethylene, polypropylene, polystyrene or polyvinyl chloride, for
example, may serve as the decorative film or foil. The
thermoplastic resin is preferably one that has good adhesion
characteristics to the material of the A layer, so that the
decorative film can be thermally fixed or laminated on the support
without the need to apply an adhesive layer.
[0112] Alternatively, it may be provided that a decorative film is
applied to support material according to the disclosure and fixed
thereon with the aid of a coating, in particular with the aid of a
radiation-curable coating.
[0113] Further according to method step f), a decoration simulating
a decorative template may be applied to at least a partial area of
the support. In this case, the decoration may be applied by "direct
printing". For the purposes of the disclosure, the term "direct
printing" is understood to mean the application of a decoration
directly to the support of a panel, or to a fibre material layer or
decorative substrate which is attached to the support but not
printed. Various printing techniques, for example flexographic
printing, offset printing or silkscreen printing may be employed.
In particular, inkjet processes or laser printing processes for
example may be used as digital printing techniques.
[0114] The decorative layers may also be formed from a dye and/or
ink which in particular is radiation-curable. For example, a
UV-curable dye or ink may be used.
[0115] The decorative layers may each be applied with a thickness
in a range from .gtoreq.5 .mu.m to .ltoreq.10 .mu.m.
[0116] Besides an image of the decorative template which is
positive with regard to colour and/or structure, it may further be
provided to apply a corresponding negative image of the decorative
template. In detail, as is known for example from positive staining
and negative staining for wood materials for example, the colour
impression of a grain for example may be reversed by the use of
digital data, with the result that a negative is created with
regard to the colour and in particular lighter and darker regions.
Besides the colour impression, a similar result is also possible
for the structure applied, so that a negative can be created with
regard to the structural variant. Effects of such kind can also be
integrated in a production process on the basis of digital
three-dimensional data easily and without lead time or
conversion.
[0117] According to method step g), an application of a protective
layer to at least a partial area of the decoration may be provided.
A layer of such kind for protection of the applied decoration may
be applied for protection of the applied decoration in a subsequent
method step for protection of the applied decoration, in particular
to protect the decorative layer from wear or damage due to dirt,
the effects of moisture or mechanical effects such as abrasion, for
example. It may be provided for example that the wear and/or cover
layer is applied over the printed support as a prefabricated
overlay layer, possibly based on melamine, and is bonded therewith
by the effects of pressure and/or heat. It may further be preferred
that a radiation-curable composition, such as for example a
radiation-curable coating like an acrylic coating is also applied
to form the wear and/or cover layer. It may then be provided that
the wear layer includes hard substances such as for example
titanium nitride, titanium carbide, silicon nitride, silicon
carbide, boron carbide, tungsten carbide, tantalum carbide,
aluminium oxide (corundum), zirconium oxide or mixtures thereof to
increase the layer's wear resistance. The application may be
carried out for example using rollers, with rubber rollers or by
means of pouring apparatuses.
[0118] The cover layer may also be partially cured initially and a
final coating with a urethane acrylate and final curing with a
gallium radiator for example may be carried out subsequently.
[0119] The cover and/or wear layer may further contain means for
reducing static (electrostatic) charging of the final laminate. For
this purpose, it may be provided for example that the cover and/or
wear layer contains compounds such as choline chloride. The
antistatic agent may be present in the cover layer and/or
composition for forming a wear layer for example in a concentration
between .gtoreq.0.1 wt % and .ltoreq.40.0 wt %, preferably between
.gtoreq.1.0 wt % and .ltoreq.30.0 wt %.
[0120] It may further be provided that a structuring, in particular
a surface structuring matching the decoration is worked into the
protective layer or the wear or cover layer by the introduction of
pores. In this context, it may be provided that the support board
already has a structuring and a printing tool for application of
the decoration and the support board are aligned with each other
depending on the structuring of the support board which is captured
by optical processes. For aligning the printing tool and the
support board with each other, it may be provided that a relative
movement between the printing tool and the support board with
respect to each other required for the alignment is caused by a
displacement of the support board or a displacement of the printing
tool. It may further be provided that a structuring of the
decorative panels takes place after the cover and/or wear layer has
been applied. To this end, it may preferably be provided that a
curable composition is applied as a cover and/or wear layer and a
curing process is carried out only to the extent that a partial
curing of the cover and/or wear layer takes place. Suitable tools
such as a hard metal texture roller or a stamp impress a desired
surface structure in the layer which has been partially cured in
this way. The impression is carried out in accordance with the
applied decoration. In order to guarantee sufficient agreement
between the structure to be created and the decoration, it may be
provided that the support board and the stamping tool are aligned
with each other by corresponding relative movements. After the
desired structure has been introduced into the partially cured
cover and/or wear layer, a further curing of the now structured
cover and/or wear layer is carried out.
[0121] In this context, it may also be provided that a structuring
of the surface is created by means of a process for producing a
structure on a surface in which a liquid base layer is first
applied to the surface of the workpiece and then a multiplicity of
droplets are sprayed into the still liquid base layer in such
manner that the layer thickness of the base layer is altered at the
sites where the droplets land. In this way, depressions are created
in the previously applied liquid base layer by the spraying of the
droplets. Finally, the liquid base layer is fixed. This may be
carried out by heat or by electromagnetic radiation depending on
the material of the base layer.
[0122] Additionally, a reverse image may be applied to the side
opposite the decoration side.
[0123] According to variant of the disclosure, the tempering step
described earlier may be carried out in particular after the
previously described process step g) or h). In particular, it may
be provided that a board with a plastic support material according
to the disclosure which is obtained upon completion of step g) or
h) and then decorated is first divided into areas to receive
individual decorated panels, which then undergo a profiling of at
least two of the panel edges to form complementary locking means,
by which panels may be connected to each other. A tempering step
may then be performed preferably only after the panel has been
divided up and or received the profiling. The provision of a
tempering step for a panel that has been previously profiled is a
particularly preferred variant.
DRAWINGS
[0124] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure.
[0125] In the following text, the disclosure will be explained
further with reference to the figures and an exemplary
embodiment.
[0126] FIG. 1 shows a schematic representation of a variant of a
multi-laminate plastic support material according to the
disclosure; and
[0127] FIG. 2 illustrates the method workflow for producing a
film-like multilayer composite with the layer sequence A-B-A for a
multi-laminate plastic support material according to the
disclosure.
[0128] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0129] Example embodiments will now be described more fully with
reference to the accompanying drawings.
[0130] FIG. 1 shows a schematic representation of a variant of a
multi-laminate plastic support material 100 according to the
disclosure. The multi-laminate plastic material 100 includes a
plurality N of A-B-A layer sequences 110. In the schematic
embodiment shown, the number of A-B-A layer sequences is 4 (N=4).
In general, the number of A-B-A layer sequences 110 may be between
3 and 250 (250.gtoreq.N.gtoreq.2). The A layer includes a first
thermoplastic resin and the B layer includes a second thermoplastic
resin. The first thermoplastic resin is preferably a virgin plastic
and the second plastic a recycled plastic. The thermoplastic resins
are preferably polyethylene terephthalates. These are available in
large quantities particularly as recycled material from the
recycling of food packaging. The thermoplastic resin of the A layer
is preferably a glycol-modified polyethylene terephthalate (PET-G).
Surprisingly, it was found that the glycol-modified PET can
function as a sealing and/or adhesive layer between the A-B-A
multilayer composites. The A-B-A layer sequence 110 may have a
total layer thickness between 100 .mu.m and 2000 .mu.m. In this
case, it may be provided that the layer thickness of the B layer
has a value between .gtoreq.100% and .ltoreq.3000% of the layer
thickness of the A layer. In other words, the B layer may have the
same layer thickness as an A layer or it may be up to 30 times
thicker than said A layer. In particular, it may be provided that
largest part of the total layer thickness of the multilayer
composite A-B-A is provided by the B layer. Accordingly, it may be
provided for example that the layer thickness of the B layer
constitutes .gtoreq.50% of the total layer thickness of the
multilayer composite, preferably .gtoreq.60%, particularly
.gtoreq.70% and more preferably .gtoreq.90% of the total layer
thickness. The thermoplastic resin of the B layer may preferably be
a plastic that is modified with filler materials, such as talcum
for example, in particular a PET. The multi-laminate plastic
support material 100 according to the disclosure may be made into a
film stack 120 by stacking film-like multilayer composites 110 one
on top of the other, wherein the stack is then compressed together
under the effects of pressure and temperature. The pressure to
supply during the compression according to the disclosure may be in
a range from .gtoreq.0.5 MPa to .ltoreq.25 MPa, preferably in a
range from .gtoreq.1 MPa to .ltoreq.15 MPa. The target temperature
in the core of the film stack may preferably be set in a range
between .gtoreq.65.degree. C. and .ltoreq.140.degree. C., in
particular in a range between .gtoreq.80.degree. C. and
.ltoreq.120.degree. C. This ensures good bonding between the
individual three-layer film-like multilayer composites 110. For the
compression process, a preheating of the three-layer film-like
multilayer composites 110 may be provided to .gtoreq.80 to
.ltoreq.135.degree. C. for example. Suitable heat sources for this
may be for example a heated roller, hot air, an IR radiator, in
particular an NIR radiator or a microwave radiator or combination
of these. The compression may take place for example in a dual-band
press, so that and endless material is produced in a continuous
process. It may be provided that the exposed surfaces of the A
layer are pre-treated with a corona treatment before the film-like
multilayer composites 110 are stacked to form the film stack 120.
After the compression of the film stack 120 to form the
multi-laminate plastic support material according to the
disclosure, it can be cooled down and cut to the desired size.
[0131] FIG. 2 illustrates the method workflow for producing a
film-like multilayer composite with the layer sequence A-B-A for a
multi-laminate plastic support material according to the
disclosure. According to the disclosure, it may be provided that a
film-like multilayer composite with the layer sequence A-B-A is
produced by co-extrusion using a feedblock 220 and sheet extrusion
die 230. This process may make use of two co-rotating twin-screw
extruders 210, 211 for example. A main extruder 210 may be used to
produce the material for the middle layer B, and it may be provided
that this extruder has two lateral feeds. These lateral feeds may
be used for mixing filler materials. The second twin-screw extruder
211 may be used to produce the thermoplastic resin for two A-type
layers. This extruder may also be equipped with lateral feeds to
enable mixing of additional constituents. In order to be able to
remove any moisture and/or monomers from the polyester melts in the
extruder, provision may be made to install a high-vacuum venting
system in both twin-screw extruders. The polymer melts from both
extruders 210, 211 may be introduced into a feedblock 220
separately from one another. While the melt from the main extruder
210 forms the type B middle layer, the material from the
co-extruder 211 is directed above and below the middle layer B and
forms the two type A outer layers. The three-layer melt may then be
passed through a sheet extrusion die 230. This die serves to create
a uniform layer distribution over the entire intended film width. A
number of different variants may be implemented for the cooling
process which is carried out subsequently. For example, the melt
may be cooled by means of a calender roller system. A chill roll
may also be used. In this context, an air knife and a vacuum
chamber may fulfil the function of ensuring that the melt lies
evenly on the chill roll.
[0132] The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not
intended to be exhaustive or to limit the disclosure. Individual
elements or features of a particular embodiment are generally not
limited to that particular embodiment, but, where applicable, are
inter-changeable and can be used in a selected embodiment, even if
not specifically shown or described. The same may also be varied in
many ways. Such variations are to be regarded as a departure from
the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
* * * * *